Positioning:
Iconic Japanese sports car, celebrated for its rotary engine and driving dynamics. This manual focuses on a critical mechanical component ensuring performance.
Competitive Landscape:
Competed against other lightweight sports cars of its era, but the rotary engine and unique chassis set it apart. The manual transmission was a key element of its driver-focused appeal.
Vehicle Highlight:
Mazda RX-7 FD3S is renowned for its twin-rotor Wankel engine and exceptional handling, a direct result of its lightweight chassis and balanced design.
Value To Owner:
Essential for maintaining the performance and longevity of the RX-7's unique manual gearbox, enabling enthusiasts to perform repairs and upgrades with factory accuracy.
Primary Focus:
Manual Transmission (M-Type Gearbox)
Additional Coverage:
Non-turbo models
Estimated Page Count:
400-600 pages (typical for a factory workshop manual)
Type:
Factory Service Workshop Manual
Language:
English (assumed based on common availability for North American market manuals)
Format:
Printed Book (common format for this era of manuals)
Transmission Internals:
Disassembly, inspection, reassembly of gears, synchros, bearings, shafts, and selectors.
Transmission Housing:
Inspection and repair of housing components, seals, and mounting points.
Clutch System:
Diagnosis and repair related to clutch actuation and engagement (master/slave cylinders, lines).
Shifter Linkage:
Adjustment, inspection, and repair of shift levers and connecting mechanisms.
Driveshaft And Differential Interface:
Procedures for removal/installation and associated components like U-joints or CV joints at the transmission output.
Disassembly And Reassembly:
Step-by-step guides for complete gearbox tear-down and reconstruction.
Troubleshooting:
Diagnostic charts and procedures for common issues like noise, difficult shifting, or leaks.
Inspection And Measurement:
Guidelines for checking wear on gears, bearings, and synchronizer rings, including specific tolerances.
Adjustment:
Procedures for adjusting clutch linkage or shift cables if applicable.
Fluid Service:
Drain and fill procedures, fluid type recommendations, and capacity.
Depth:
Comprehensive rebuild level, covering all internal components and detailed specifications.
Diagnostic Capabilities:
Advanced troubleshooting for mechanical and hydraulic aspects of the transmission and clutch system.
Component Replacement:
Detailed instructions for replacing specific internal parts like gears, bearings, seals, and synchros.
Digital Format If Applicable:
PDF (if a digital reproduction)
Print Quality:
High-resolution scans, clear diagrams and text (for digital reproductions).
Binding Type:
Perfect bound or spiral bound (common for workshop manuals).
Paper Type:
Durable, matte finish paper suitable for workshop environments (for printed manuals).
Engine Type:
Rotary (Wankel) Engine
Engine Code:
13B-REW (Twin-rotor, sequential twin-turbocharged)
Displacement:
1.3 Liters (654cc x 2 rotor chambers)
Horsepower:
252 hp @ 6500 rpm (initial JDM spec); 255 hp @ 6500 rpm (later JDM/export spec)
Torque:
217 lb-ft @ 5000 rpm (initial JDM spec); 217 lb-ft @ 5000 rpm (later JDM/export spec)
Fuel Delivery:
Sequential Electronic Fuel Injection (EFI)
Turbocharging:
Sequential Twin-Turbocharged System
Type:
M-Type 5-Speed Manual Transmission
Automatic Option:
Available (but this manual specifically excludes automatic transmission models)
Gear Ratios:
Specific gear ratios detailed within the manual (e.g., 1st: 3.387, 2nd: 2.190, 3rd: 1.551, 4th: 1.155, 5th: 0.848, Reverse: 3.238 - typical for early FD)
Fluid Type:
Manual Transmission Fluid (MTF), specification like GL-4 or GL-5 often recommended (specific spec to be confirmed in manual).
Fluid Capacity:
Approx. 2.0 - 2.2 liters (specific capacity to be confirmed in manual).
Clutch Type:
Hydraulically operated, single dry plate clutch
Transmission Fluid Change:
Typically recommended every 30,000-60,000 miles (or as specified in the vehicle's owner's manual/service schedule, this manual will provide the precise factory guideline).
Clutch Inspection:
Periodically, checking for wear and proper engagement as part of regular service.
Transmission Fluid Spec:
Specific viscosity and API rating for MTF (e.g., SAE 75W-90 GL-5 is common, but factory spec is crucial).
Clutch Fluid Spec:
DOT 3 or DOT 4 brake fluid (for hydraulic clutch actuation).
Transmission Common Issues:
Wear on synchros (especially 5th gear), bearing noise, clutch release issues, potential for seal leaks.
Clutch Common Issues:
Clutch chatter, difficulty shifting gears due to worn clutch components or hydraulic issues.
Synchro Ring Replacement:
Detailed steps for accessing and replacing worn synchronizer rings.
Bearing Replacement:
Procedures for replacing input shaft, output shaft, and layshaft bearings.
Mazda Rotary History:
Mazda's pioneering work with the Wankel rotary engine, dating back to the Cosmo Sport.
Rx7 Generations:
The RX-7 has had three distinct generations: SA/FB (1st Gen), FC (2nd Gen), and FD3S (3rd Gen). The FD3S is considered the pinnacle of the RX-7 lineage.
Production Years:
1992-2002
Manufacturing Location:
Hiroshima, Japan
Motorsport Achievements:
Successful in various racing series, including IMSA GTU and Grand Touring, and SCCA Production classes.
Car And Driver Awards:
Car and Driver 'Ten Best' list multiple times during its production run.
Performance Magazine Ratings:
Consistently received high marks from automotive publications for its handling, braking, and engine performance.
